Diagnose. Predict. Prevent. Improve.

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Failures in reliability often begin unseen, through contaminants, corrosion, or fouling, until they escalate into costly shutdowns or catastrophic damage. Jonell’s Audit & Consulting Services provide a structured, multi-faceted approach that helps customers understand contamination behavior and its impact on critical assets. Services are designed to reduce operating risk, extend equipment life, and embed continuous improvement into daily operations.

Service Layers

1. Filter Service (Evaluation of Installed Systems)

Focus: Ensure existing filtration installations remain effective, relevant, and aligned with current process conditions.

• Upstream/downstream sampling and benchmarking (TSS, TSM, PSD, morphology, compatibility)
• Live performance (re)validation against operating parameters
• Preventive maintenance programs to avoid unexpected failures
• KPI trending and proactive changeout planning
• Transition from one-time snapshots to continuous reliability monitoring

2. Process Audit (Single or Multiple Units)

Focus: A holistic system assessment that maps contamination pathways, identifies root causes, and protects process reliability.

• Contaminant mapping across tanks, exchangers, piping, and transfer lines
• Root-cause identification: linking contamination → process impact (OPEX, fouling, corrosion, catalyst deactivation)
• Corrective actions: feed conditioning, process modifications, handling/storage best practices, filtration upgrades
• Reliability programs aligned with API 571 damage mechanisms and industry best practice

3. Engagement Models

Single Event: One-time sampling campaign, troubleshooting study, or incident investigation.

Program Approach: Annual or multi-year contracts that combine:

• Regular field service campaigns
• Lab analysis with contaminant morphology profiling
• Trending dashboards for ΔT, ΔP, solids load, and fouling rates
• Continuous improvement loop: recommendations → implementation → revalidation

Target Applications

Refining

• Hydrotreating / Hydrocracking: Catalyst protection from asphaltenes, gums, waxes, corrosion scale; root-cause tracing back to tankage or blending
• Amine Systems (Lean/Rich): Detect foaming/corrosion drivers; validate solids-control strategies; prevent solvent losses
• Sour Water Systems (SWS): Locate solids/hydrocarbon ingress; protect exchangers and reboilers from fouling
• Tail Gas Treating Units (TGTU): Pinpoint amine carryover affecting downstream reliability
• Fuel Gas Conditioning: Eliminate lube oil, corrosion products, or slugs threatening burners/turbines
• Crude / CDU Preheat Trains: Optimize exchanger cleaning intervals; mitigate fouling via ΔT/ΔP monitoring
• Tank Management Systems: Ensure compliance with API 653 and API 2350; minimize overfill and emergency maintenance

Chemicals

• Unit Troubleshooting & Debottlenecking: Contamination source elimination to prevent off-spec product and OPEX spikes

Utilities

• Compressors: Reduce fouling and trips from aerosol/solid carryover; define inlet/coalescer specs and wash regimes
• Burners & Turbines: Protect combustion systems with effective fuel gas coalescing and solids removal
• Cooling-Water Systems: Enhance exchanger reliability by controlling biofouling and scaling

Benefits

• Improved unit reliability and uptime; reduced unplanned outages
• Early detection and prevention of corrosion/erosion per API 571
• Documented validation for licensor/EPC/internal audits
• Optimized filter life and reduced TCO
• Lower cleaning and energy costs through optimized exchanger maintenance
• Reduced compliance and emergency response costs (API 653 / API 2350)
• Increased compressor and burner reliability through aerosol/solid ingress control

Deliverables

Every engagement includes a structured output package designed to provide actionable insight and traceable documentation:

• Customized Sampling Plan & Protocols: tailored to unit conditions, covering frequency, locations, and parameters
• IntegraLabs™ Report: standardized test data, contaminant morphology, solubility behavior, and compatibility assessment
• Actionable Recommendations: filtration upgrades, PM intervals, operating set-points, handling practices
• Heat Exchanger Fouling Dashboard: ΔT/ΔP trending, predictive cleaning-window forecasts, fouling model correlation
• Tank Management Review: API 653 inspection planning, API 2350 overfill prevention gap analysis, tank cleanliness programs
• Compressor Reliability Package: inlet/coalescer specifications, wash regimes, aerosol/solid carryover tracking
• Reliability Alignment Matrix: crosswalk of audit findings to API 571 damage mechanisms and other standards
• Economic Impact Analysis: quantified cost-avoidance and savings from preventive vs. reactive maintenance, exchanger optimization, and reliability improvements
• Continuous Improvement Roadmap (for program clients): stepwise plan with milestones, KPIs, and annual trending benchmarks
• Field Trial Design & Validation: implementation support for filtration or process changes, with performance revalidation

Documented Impact

• Preventive vs. reactive maintenance: 12–18% OPEX savings; predictive programs add 8–12% plus energy savings
• Heat exchanger fouling: U.S. refinery costs $1–2.2B/year; optimized cleaning saves $40–50k per exchanger per event
• Fouling models (Ebert–Panchal, refinery case studies) support predictive cleaning windows
• Corrosion risk: API 571-aligned programs reduce catastrophic failures
• Tank integrity: API 653/2350 compliance reduces emergency maintenance costs
• Compressor efficiency: documented performance losses avoided via proper inlet filtration & coalescing